Sir Thomas Boughey Academy, Station Rd, Halmer End, Newcastle-under-Lyme, ST7 8AP.
RAEBUILD successfully completed the RAAC Roof Plank Replacement Project at Sir Thomas Boughey Academy in March 2023 on behalf of the United Endeavour Trust. Following the identification of deteriorating Reinforced Autoclaved Aerated Concrete (RAAC) roof planks that had exceeded their design life, the project involved the full replacement of the existing roof structure over the school hall, boiler room, and adjacent teaching spaces.
Following national guidance issued by the Department for Education and Local Government Association regarding the risks associated with Reinforced Autoclaved Aerated Concrete (RAAC), structural investigations identified deteriorating roof planks within key areas of Sir Thomas Boughey Academy.
The project brief was therefore developed to address the risk of structural failure and ensure the continued safe operation of the school. Two options were considered: retaining the existing RAAC planks with a protective crash deck, or fully replacing the roof structure. Following detailed assessment by the project team, full replacement was selected as the preferred long-term solution.
The works needed to be delivered within an occupied school environment while maintaining safety and minimising disruption to staff, pupils, and daily operations.
We were appointed through the Staffordshire County Council Framework and worked collaboratively with Entrust and the Academy to develop and deliver a practical, cost-effective roof replacement solution.
The project involved the careful removal of the existing RAAC planks and installation of a new structural roof system, together with upgraded insulation, waterproof roofing, rainwater goods, lighting, suspended ceilings, decorations, and associated building services.
A detailed Construction Phase Plan was implemented to safely manage the complex works within a live school environment. Temporary crash decks and roof structures were installed to protect building users during construction, while close liaison with the school ensured that all activities were carefully planned and coordinated to minimise disruption throughout the programme.
Completed in March 2023, the project successfully eliminated the risks associated with the ageing RAAC roof structure and provided the Academy with a safe, durable, and future-proof solution.
The new roof system significantly improved the building’s long-term performance through enhanced insulation, drainage, and waterproofing measures, supported by a 25-year roofing guarantee.
Delivered within the agreed programme and budget, the project was completed while maintaining the operation of the occupied school site. Through careful planning, stakeholder collaboration, and effective construction management, we provided a high-quality outcome that safeguarded the school’s facilities and ensured their continued use for pupils, staff, and the wider school community.
